Welding system



C. E. SMITH WELDING SYSTEM July 26, 1949.

2 Sheets-Sheet 1 Filed Dec 16, 1943 CLYDE E. SMITH WELDING SYSTEM Filed Dec. 16, 1945 2 Sheets-Sheet 2 J I we r1 kw E: I B. CLYDE E. SMITH 05143 I I GM Patented July 26, 1949 WELDING SYSTEM Clyde E. Smith, Warren, Ohio, assignor to The Taylor-Winfield Corporation, Warren, Ohio, a

corporation of Ohio Application December 16, 1943, Serial No. 514,491

Claims. (Cl. 171-97) This invention relates to electric resistance welding systems and more particularly to improved methods, circuits, and devices for translating the electrical energy to the weld and for controlling the operation of the translating means employed. A primary object of the invention is the provision of an improved system for furnishing direct current energy to the weld from an alternating current source. The application of such current, particularly of large values and short durations .of flow, has been found advantageous for certain welding operations principally in the field of alloys and while it has heretofore been proposed to employ systems utilizing a welding transformer and a rectifier interposed between the output of the transformer and the welding load such systems have not been amenable to proper or efiicient control. It is accordingly a more specific object of the invention to provide in a welding system having means to furnish a uni-directional welding current from an alternating current source an improved arrangement for controlling the flow of welding energy. While the employment of the rectifier and the consequent furnishing of the uni-directional current to the welding machine proper lessens welding inconsistency which is due to the inductive effect of the adjacent welding current carrying parts of the machine and of the variable position of the work in the throat of the machine variations in line voltage continue to lend inconsistency to the welding results and another object of the invention is to eliminate this inconsistency entirely in a welding system of the kind involved.

A further object of the invention is the provision of improved, simplified and more economic circuit arrangements for controlling the flow of electrical energy from a polyphase source of current to a welding load. Normally, when the welding machine is once set up an effective range of control of the welding energy furnished may be maintained within 50% of the capacity range of the machine. This control may include automatic voltage compensation as mentioned above and, in addition, the usual heat control to provide an adjustment to compensate for variations in the dimensions or character of the stock and in the quality of the weld being produced. In the conventional three-phase three-wire supply circuit an effective control of more than ample range may be provided by controlling in a modu- A still further object of the invention is the provision of an improved circuit arrangement for modulating the flow of energy from a supply circuit to a load circuit in accordance with variations in voltage in the supply circuit.

Yet another object of the invention is the provision of improved and materially simplified circult arrangements for modulating the flow of energy from a polyphase source of electrical power to a welding load in accordance with variations in the voltage of the source.

Other objects of the invention include the provision of improved circuit arrangements for actuating a welding pressure changing device in timed sequence following the initiation of the flow of welding current and for utilizing such control in a direct current welding system.

Other objects and advantages of the invention will become apparent upon consideration of the following detailed specification and the accompanying drawing wherein there is specifically disclosed a preferred embodiment of the invention.

The single figure of the drawing, on two sheets, isa schematic diagram of a spot welding system constructed in accordance with the principles of the invention.

Referring to the drawing, Li, L2 and L3 will be the line conductors of a conventional threephase source of alternating current while reference numeral I i indicates a welding transformer, the primary of which is connected in star and adapted to be connected to the line conductors Ll, L2, L3 while the secondary of which is connected in delta for furnishing low voltage electrical power to the full wave welding rectifiers l2. Rectifiers l2 are of the dry plate type having sufiicient surge capacity to handle the heavy currents normally employed in welding operations and, as shown, the output thereof is connected to fixed electrode l3 and to the movable electrode ll of the welding machine. While I have shown the electrodes as being of stud form, it should be apparent that the invention is equally applicable to welding systems generally including seam lating manner the conduction in but one of the welders employing wheel electrodes.

Conductors LI and L2 are arranged to be con nected, in the preferred and illustrated embodiment of the invention, to the primary winding of the transformer l I through the contactors i5 and I6 of a relay I! having an energizing coil IS. The third conductor L3, of the source is connected to the primary of transformer ll through the valves I9 and 20, connected in inverse parallel, and preferably of the ignitron type. As such, valves I9 and 20 each has an 'anode, a mercury pool cathode and an ignition electrode arrangedto be energized at controlled times during the half cycles of the current source.

-For'this purpose, a discharge device 2| of the gas filled type is connected across the anode and ignition electrode of the valve l8 and a similar device 22 is provided for the valve 28. Normal negative grid bias sumcient to hold the device 2i non-conducting is furnished by a rectifier 23 deriving energy from a control current line 24 through a transformer 25. Line 24 may be energized through a transformer 28 on the conductors L2, L3. The output of rectifier 23 developes a voltage across the resistor 21 which is in the grid biasing circuit for the device 2!, the

in the grid biasing circuits of the devices 38 and 4s and also in series with these circuits is a resistor II the effect of which will be explained below. Such circuits may readily be traced from the cathodes of the devices 38 and 48 through conductor 42, resistor 88, conductor 83, resistor circuit including the secondary 28 of the grid I transformer 25. Resistor 38 is in the grid circuit for device 22, which circuit also includes the secondary winding 32 of the grid transformer 33.

The primary 34 of transformer 28 is in a circuit which may be traced from an end terminal 38 of a center-tapped secondary winding of the transformer through conductor 38. winding 34, conductor 31, anode-cathode of a grid controlled gas discharge device 38, potentiometer 3t, contactor 4ft of a relay 4! having an energizing coil 42, and conductor 48 to the center tap 48 of said secondary winding. The primary 44 ot transformer 33 is in a circuit which may be traced from the other end terminal 48 of said secondary winding through conductor El, winding 46, conductor 48, anode-cathode of a grid controlled gas discharge device 49, and then through resistor 39 and contactor 40 to the center tap iii. Thus by the initiation of conduction in the tubes 88 and 48 at predetermined times during the positive or negative half cycles of potential appearing across the valves I8 and 26 the grid transformers 29 and 33 will be impulsed to permit the valves is and 28 to translate predetermined portions of the respective half cycles of energy as will be well understood.

To provide for a base or heat control through the devices 38 and 48 of the quantity of energy transmitted by the valves i8 and 20 I provide a phase shifting circuit 58 the input of which is connected to a center-tapped winding SI of a transformer 52, the primary of which is connected to the control current line 24 and the output of circuit 50 is impressed on the primary windings 53 and 54 of grid transformers 55 and 88,- respectively. The secondary of transformer 85, indicated by reference numeral 51', is in the grid circuit of the tube 38 while the secondary 88 of the transformer 58 is in the grid circuit of the tube 48. Thus conduction in tubes 38 and 48 is initiated during the respective half cycles at times determined by the phase deviation efiectedby the adjustment of the circuit 58 and in this manner a basic control or adjustment of the total energy furnished is attained.

To provide compensation for voltage fluctuation in the supply circuit whereby a predetermined constant current is furnished the weld irrespective of variations in the line voltage I introduce in the grid biasing potentials furnished the control devices 38 and 48 a direct current component which varies in accordance with line voltage conditions. For this purpose a rectifier l8 deriving energy from transformer 52 is employed to develope a constant reference potential across a resistor ill and this resistor 88 is placed with variations in line voltage and in opposition to the potential developed across resistor For this purpose a rectifier deriving energy from line 24 through transformer VET oi the voltage regulating type is provided to develop a uniform potential across a resistor 86, a filter 5? being employed to smooth out the ripples in the output. Resistance 38 is provided with a sliding tap 88 which is connected to the grid end or resistor 8i by means of the conductor so. Also connected across the output of rectifier es and ter 6i is the anode-cathode ot a grid-controlled space discharge device 18 and a resistance ii in series. The latter is provided with an adjustable. top 12 which is connected to the cathode and of resistor N by means of conductor it. e cur rent flowing in tube 18 determines the potential at tap l2 and consequently the potential at se sister 8!. As the tube It draws more current the voltage at 88 is raised thus driving the direct current component of the grid bias on the tubes 38 and 48 more positive, forcing them to conduct earlier the half cycles or the voltage wave.

Conduction in tube is is controlled in ee= cordance with the voltage in the current supply line (L2, L8 in the embodiment illustrated) by means now to be described Connected across the lines L2, L8 through transformer 2G and le 24 is the primary winding E5 of a transformer 16 the secondary ill of which feeds a full wave rectifier It which is preferably oi the dry plate.

type and the output of which is impressed across a relatively small capacitor it and a parallel resistance as of a potentiometer. The negative end of resistance 88 is connected to the cathode of tube 18 through resistor it while the movable tap of the resistance 83 is connected to the control grid of the tube 18 through the usual grid re= sistor 8i. Thus as the voltage drops in the conductors L2, L3 the output of rectifier it is diminished as is also the potential developed across resistance 8t and therefore the positive bias on tube 10 is lowered causing it to conduct less cur rent the eflect of which is to cause earlier conduction in the control-devices 88 and so as ex- Diained above- While I have shown the line voltage determining means (reee) as being responsive onlyto the voltage of the phase carried by conductors L2, L3, it should be apparent that the full wave three-phase rectifier it may lly as well be powered by all the phases if it is desired to do so. i

The improved pressure changing valve solenoid actuating circuit of the invention will now be described. This circuit consists essentially of a solenoid .energizing circuit and a control circuit to initiate the flow of energy in the energizing circuit at an accurately timed interval following the establishment of a reference condition which in the present case is the initiation of flow of current through the weld. Reference numeral 83 indicates a floating double bellows interposed.

in the line of drive between the primary actuatthe welding machine. Assembly 88 having an exhaust valve 88 operated by solenoid 88 may be of the type specifically disclosed and claimed in co-pending application Serial No. 482,638, now Patent No. 2,363,753 or M. A. Seelofi and C. E. Smith. To perform a welding operation a valve 81 which is normally automatically actuated by appropriate sequencing circuits is provided to admit fluid pressure to the upper end oi cylinder 84 to effect downward movement of the assembly 83 and electrode I4. A switch 88 forms a part of assembly 83 and as explained more in detail in said co-pending application, this switch closes upon-yielding of the assembly 83.

Solenoid 88 is arranged to be energized by discharge or a capacitor 88 efi'e'cted by conduction in a grid controlled gas discharge device 88, the discharge circuit being traceable from the positive terminal oif capacitor 88 through conductor 8|, contactor 82 of a relay 83 having an actuating coil 84, conductor 85, contactor 88 of relay 88, conductor 81, coil 88, conductor 88, tube 88. and conductor 88 to the negative terminal capacitor. Capacitor 88 is arranged to be charged from control current line 24 through transformer I88 and rectifier I8I of the controlled gaseous type and to control the potential to which capacitor 88 is charged a potentiometer has its resistance I82 connected across the capacitor and a movable tap thereof connected to the control grid of rectifier I8I through conductor I88, the grid end portion of potentiometer I84, conductor I85. and grid resistor I86. A constant biasing potential is developed across the resistance element of potentiometer I84'by a rectifier I81 deriving energy from line 24 through a transformer I88. The

polarities of the potentials are as indicated on the drawing and it should be apparent that as the potential across resistance I82 raises to a predetermined adjusted value conduction in rectifier I8I will be interrupted and remain interrupted upon'the momentary opening of contactor I88 A space discharge device H8 is connected across capacitor 88 through lead 8i, contactor 82, conductor Ill, and resistor III. The cathode and control grid or tube II8 are coupled by means of resistor I I 8 so that the tube is normally at zero bias and begins to draw full current immediately upon closure oi contactor 82 which oc curs at the start of the fiow of welding current. Thus substantially the full voltage of the capacitor 88 appears across the resistor III; In parallel with resistor H8 and tube H6 is a grid controlled gaseous discharge device I25, the circuit oi the same being traceable iromlead III, anode-cathode of tube I28, conductor I28, a timing capacitor I28, a variable resistor I28, a movable tap I38, and the negative end of resistance I82 to the opposite terminal of capacitor 88. Tube I is normally held non-conductive by the negative bias impressed through resistor I3I, which resistor normally carries no current and which is connected to the negative end of resistor H8.

Conductor III which is connected to the positive side of the output of rectifier I2 is connected directly to the cathode of tube H6 while the control grid or grids of the tube is connected directly to the conductor II2 which leads from the negative side of the rectifier output. Upon appearance of rectifier voltage in the leads III and H2 conduction in tube II8 is thus substantially diminished or cut oil thereby dividing the voltage of the capacitor 88 between resistors H8 and iii. The drop in resistor I3I, being in opposition to the normal grid bias impressed on the tube I25 initiates conduction in this tube and commences the charging of timing capacitor I28 through the circuit above outlined. By means of certain arrangements now to be explained conduction in tube 88 is initiated upon the capacitor I28 attain- 40 ing a predetermined charge, the time required to placed in the primary circuit of transformer I88.

Contactor I88 is arranged to be opened momentarily by a coil II8 which is energized during fiow of welding current by means of the conductors III and H2. The charging circuit for capacitor 88 further includes a current limiting resistor H3 and a contactor II4 of the relay 83 in series across a current limiting resistor II! of greater value than resistor II3 so that immediately upon reclosure of contactor I88 (cessation of welding current) the charging can proceed at a high rate.

Energizing coil I8 of relay I1 is arranged to be energized from line 24 through a transformer II5, conductor H8, conductor III, switch 88,

conductor H8, and a timer II8 which may be of the type which opens a circuit therethrough upon the expiration of a preselected period of time. Switch 88 likewise controls the energization of coil 42 of relay H from transformer II5 through conductors I28, I2I, H8, and timer II8. Similarly switch 68 controls the actuation of relay 83 from transformer II5 through conductors I28, I22, I23, H8, and timer 8. Thus upon the application of proper welding pressure welding current begins to fiow and all the control circuits are conditioned for operation. Closure of contactors 82 and 88 of relay 83 conditions the energizing circuit for solenoid 88 as explained above and the closure of contactor 82 further conditions a timing circuit, now to be described, the function 01' which is to control the time of energization oi solenoid 88.

attain such charge being determined by the setting of the variable resistance I28. A source of grid biasing potential for tube 88 is provided by the rectifier I32 deriving energy from transformer I88 and impressing its output across a capacitance I83 and the resistance element of a potentiometer I34. The adjustable tap of potentiometer I34 is connected to the control grid of tube 88 through grid resistor I35 and the grid return circuit may be traced through potentiometer I34, conductor I21, resistor I28, conductor I28, a resistor I38, conductor I31, potentiometer I82, and conductor 88 to the cathode of the discharge device 88. Upon the capacitor I28 attaining a preselected charge and a consequent development of sufllcient potential across resistors I38 and I28 which is in opposition to the normal negative bias impressed on device 98 conduction is initiated in the discharge device 88 to dump the energy from capacitor 88 into the coil 86 through the energizing circuit therefor outlined above. In this manner solenoid 86 is furnished with suflicient energy to properly actuate the relief valve at the expiration of an accurately measured interval following the initiation of fiow of welding current to the electrodes I3 and I4. A normally closed contactor I38 on relay 83 effects the complete discharge of th timing capacitor I28 between successive welding operations.

It should be understood that a control system of the nature described above is normally utilized in a complete welding machine having appropriate circuits and devices for effecting continuous automatic operation of the same. For example, such machine may, following the teaching of the prior art, include means to periodically actuate valve :1 and further means operable in timed sequence following actuation of valve l1 to turn or raise the piston in cylinder 34 to open the electrodes and the switch 83 following the completion of a welding operation. The circuits of the control system are then restored to their conditions indicated in the drawing in preparation for the next succeeding welding cycle.

It should now be apparent that I have provided an improved electric resistance welding system and improved circuits having especial utility in connection with such systems which accomplish the objects initially set out. The invention provides a simplified and wholly practical arrange-.

ment for controlling the flow of energy from a multiple phase alternating current source to a direct current load including the iurther modification of the control-in accordance with variations in the voltage of the source. The invention also provides an entirely practical and accurate circuit for eiIecting the timed application 01' a change in a critical welding condition during a welding cycle as explained above and, moreover, teaches how such a'circuit may be advantageously incorporated in a direct current resistance welding system.

The above specifically described embodiment of the invention should be considered as illustrative only as obviously many changes may be made therein without departing from the spirit or scope of the invention. For example, insofar as certain obvious aspects of the system are concerned the mechanical contactors I 5 and I which control conduction in two of 'the current source conductors may, if desired, be replaced by suitable electronic discharge devices connected back to back as will be understood. In this case the voltage compensation control feature 01' the invention would be'applied to each of the phases controlled by electronic devices, it being observed that in accordance with statements made above the single voltage responsive circuit including the rectifier -I8 may be employed to vary the fixed direct current component of control grid bias of all the control devices. Reference should therefore be had to the appended claims in determining the scope of the invention.

What I claim is:

1. In an electric power system having a multiple phase source of alternating current, a load circuit, and translating means to furnish said load circuit with electrical energy from each of the phases of the source; the combination of switching means to connect and disconnect one phase of said source with said translating means, means comprising a pair- 01' reversely connected electric discharge devices for interconnecting another of the phases of said source with said translating means, said devices each having a control element to initiate conduction in said devices at predetermined points in the voltage wave of the said another phase of said source, means comprising a phase shifting circuit to determine the points in the said voltage wave at which conduction in said devices is initiated to effects basic control over the quantity of energy furnished said load circuit, and means to shift said conduction points in response to voltage variations in said source whereby the quantity of energy turnished said load circuit is maintained substantially constant regardless of voltage variations in said source.

2. In an electric power system having a multipie phase'source 'oi alternating current, a load circuit, and translating means to furnish said load circuit with electrical energy from each of means comprising a pair or reversely connected electric discharge devices for interconnecting another 01' the phases of said source with said translating means, said devices each having an elec-' trical element to initiate conduction in said devices at predetermined points on the voltage wave or said another phase oi said source, and

means to shift said conduction points in response to voltage variations in said source whereby the quantity of energy furnished said load circuit is maintained substantially constant regardless of voltage variations in said source.

3. In an electric power system having a multiple phase source of welding current, a load circuit, translating means. to furnish said load circuit with electrical energy from each of the phases of the source, and an initiatingswitch: the combination of means operable automatical- 1y upon closing or said switch to connect one phase of said source with said translating means, means comprising a pair of reversely connected electric discharge devices for interconnecting an-' other of the phases of said sourcewith said translating means, said devices each having a control element to initiate conduction in'said devices .at'

predetermined points in the voltage wave of said another phase of said source, an energizing cir-' cuit for said control elements, and means to condition said energizing circuit automatically upon closing of said initiating switch.

4. A system according to claim 3 further including means in'said energizing circuit to shift the conduction points of said devices in response to voltage variations in said source whereby the quantity of energy furnished said load circuit is maintained substantially constant regardless of voltage variations of said source. I

5. A system according to claim 3 further including means in said energizing circuit for shifting the conduction points in said devices with respect to the voltage wave of said another phase of said source to eflect a basic control over the quantity of energy furnished said load circuit, and further means in said energizing cir-' cult to shift said conduction points in response to voltage variations in said source whereby the quantity of energy furnished said load circuit is maintained substantially constant regardless oi. voltage variations in said source.

CLYDE E. SMITH.

REFERENCES crrnn The following referenlces are of record in th flle of this patent:

UNITED s'ra'rns PATENTS Mahoney Aug. 27, 1946 

